Increased strain rates change the mechanical behavior of a material. It is important to study the high strain rate properties of the materials to achieve optimum design, further weight reduction and safer vehicles

A study project on evaluation the effect of 10% ethanol blended gasoline (E10) fuel versus commercial gasoline (E0) on polymeric materials (Elastomers and Plastics) used in automotive components was undertaken by ARAI. Common elastomers and plastics used in automotive components were tested as per the guidelines given in the SAE J 1748 for non-metal compatibility study.

ObjectiveTo evaluate the effect of 10% ethanol blended gasoline (E-10) on the properties of various automotive materials (including four elastomers and three plastics) in comparison with the effect of pure gasoline.

Significance

Increasing costs of petroleum fuels and environmental concerns are driving the auto industry to look for cleaner, less expensive and easily available alternative to gasoline.

Ethanol blended fuels are fast emerging as alternative to pure gasoline because of the reproducibility of ethanol and other cost benefits.

Compatibility with gasoline of various auto materials that come in contact with the fuels is well established.

It is required to evaluate the compatibility of these currently used materials with the new ethanol blended fuel.

Methodology

The study was carried out as per the guidelines given by Society of Automotive Engineers standard SAE J 1748.

A set of the specimens was immersed in gasoline and another in E-10 both kept at a constant temperature of 55°C for 18 weeks.

Change in material properties like Volume/swell, Weight, Appearance, Tensile strength, Elongation, Impact resistance and Hardness Shore A were measured after immersion of materials in a fuel in a periodic manner to evaluate the impact of E10 fuel on materials relative to the Gasoline. Typical results are shown below.

Applications

The material compatibility study with alternate fuels helps in assessing the compatibility of the materials tested with alternate fuels with respect to the useful life of vehicles.

The database of properties generated in this project is useful for selection of materials compatible with E-10 fuel.

Under run protection devices such as Rear under Run Protection Device (RUPD) and Lateral under Run Protection Device (LPD) are mandatory on heavy vehicles as per IS 14812 and IS 14682 respectively. Regulation for Front Under-run Protection Device (FUPD) is also in pipeline.

Some of the problems with the current technology include

Lack of universal design

Repairability

Reusability

Cost-effectiveness

Retrofitting not possible

No energy absorption

In an under-run accident, truck-bed can penetrate up to the driver compartment causing serious or fatal injuries to the car-passengers

Vehicle with RUPD

Vehicle with LPD

Methodology

To design the under-run devices with the use of different energy absorbing materials.

To validate the design and materials by computer aided engineering.

To make prototype of the under run devices.

To test the devices for its performance, energy absorbing capacity, and ease of reparability.

RUPD test being
conducted by ARAI

Applications

The energy absorbing UPD’s would help in minimizing the fatalities occurring due to vehicle under-run and hence would increase the road safety.

The UPDs would also help in avoiding the damage to the heavy vehicles due to such an under-run accident.

Chemical Characterization of Particulate Matter

ObjectiveChemical Characterization of Particulate Matter (PM) from vehicle exhaust for various species including carbon fractions, cations, anions, elements and organic molecular markers.

Significance

Knowledge of abundances of chemical species in vehicle exhaust is essentially required as an input for receptor models which are used for source apportionment studies.

Earlier, internationally available data (US-EPA) had been used for this purpose.

Considering difference in the atmospheric conditions, technology & fuel quality and its bearing on vehicle exhaust, it was needed to develop vehicle exhaust profiles specifically for Indian vehicles.

Methodology
Comprehensive data base on source profiles is generated for Indian vehicles, which includes

Chemical characterization of PM as per international standard procedures with proper QA/QC protocols.

Compilation of the chemical speciation data for the above species in the form of fraction of the total PM mass with the uncertainties in measurements associated for each parameter.

Applications
Exhaust chemical speciation data is used as a vehicular source profiles for input to receptor models for source apportionment of ambient particulate matter

Design and Development of Circulating Coolant Corrosion Test rig

ARAI has successfully designed and developed Coolant Circulating Corrosion Test
Rig as per Standard IS 5759/JIS K 2234. The test rig includes 3 spare sets of
metal coupons of Aluminum, Cast Iron, Steel, Brass, Solder, Copper as per IS
5759 / JIS K 2234. Metal Coupons for the testing as per IS 5759/JIS K 2234 are
also developed by us.

Easy availability of engine coolant test rigs and metallic test coupons as per JIS K
2234 / IS 5759 is identified as the first and foremost difficulty.

Objective

To develop circulating coolant corrosion test rig with following salient features …

Compact and robust mechanical structure, portable rig

Simulation of cooling system by using engine block- head assembly radiator,
and water pump

The test rig can be built by using targeted vehicle cooling system
components as per customer requirement.

Significance
Circulating coolant corrosion test evaluates the engine coolant under a close
approach to cooling system functioning and thus this method provides better
screening of engine coolants than possible from glassware test. The coolant is
circulated under controlled conditions using cooling system components of a
vehicle and there by maintaining a greater ratio of metal surface to coolant
volume. The test simulates conventional coolant circulation of an automotive
cooling system.

Coolant evaluation using circulating coolant test rig
Corrosion rate is evaluated through change in mass (mg/cm2) of metal strips
after test. Coolant properties like pH and reserve alkalinity are measured before
and after test to evaluate change due to circulation. A typical case study of
coolant evaluation using circulating coolant test rig is presented below.

Photographs of Strips & Solution
Before & After Test

Applications

Testing of engine coolant using rig for improved quality assurance during
formulation

Building up of competence to evaluate engine coolant under close to field
conditions